Flat Cable Power Connector with Direct Socket Engagement
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Solution Overview
Problem
Existing power connector systems for data communication require complex assembly, are not cost-effective, and lack separability and blind-matability, necessitating a reliable and cost-effective power connection between a busbar connector and power cable.
Innovation Solution
A power connector system featuring a housing with a chamber for a flat cable that directly engages a socket connector's power terminal, allowing for separable and blind-matable connections through a movable panel and engagement features that secure the connector to the busbar without additional mounting hardware.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional power connectors are used with mounting hardware and additional components, then reliable electrical connection is achieved, but device complexity and assembly time increase
Solution Approach 1:
The patent combines the power connector and cable assembly into a single integrated unit where the connector is directly mounted to the cable without separate mounting hardware. The housing contains both the electrical connection interface and the cable routing structure, merging multiple functions into one component that reduces overall system complexity while maintaining reliable electrical connection.
Solution Approach 2:
The power connector housing serves multiple functions simultaneously: it provides the electrical connection interface, houses and secures the cable, provides structural support, and enables both blind-mating and separability. This multi-functionality eliminates the need for separate mounting brackets, cable clamps, and alignment features that would otherwise be required.
2Reliability
If traditional power connectors with mounting hardware are used, then secure connection is achieved, but assembly time and manufacturing cost increase
Solution Approach 1:
The connector is pre-assembled and pre-positioned on the cable during manufacturing, with the housing already configured to receive the blade interface. This preliminary assembly eliminates the need for field installation of mounting hardware and cable attachment, allowing for rapid plug-and-play installation that significantly improves assembly speed while maintaining secure connection.
3Reliability
If traditional power connectors are used, then electrical connection is achieved, but blind-matability and separability are lost
Solution Approach 1:
The power connector system is divided into separable modules: a blade component that interfaces with the socket, a housing that contains the cable, and the cable itself. This segmentation allows the connector to be easily inserted and removed from the busbar while maintaining reliable electrical connection during use, enabling both blind-matability and separability.
Data Source
AI summary
A power cable connector includes a housing having a mating end and a cable end. The housing has a chamber extending between the mating end and the cable end. The housing has an engagement feature configured to engage a socket connector extending from a substrate. A flat cable is received in the chamber. The flat cable extends from the cable end. The flat cable has a mating portion extending from the mating end. The mating portion is configured to be received in the socket connector such that the flat cable directly engages a power terminal of the socket connector.